Finfet with sloped surface at interface between isolation structures and manufacturing method thereof

ABSTRACT

A semiconductor device includes a substrate, a first insulating structure, a second insulating structure, at least one first active semiconductor fin, and at least one second active semiconductor fin. The first insulating structure and the second insulating structure are disposed on the substrate. The first active semiconductor fin is disposed on the substrate and has a protruding portion protruding from the first insulating structure. The second active semiconductor fin is disposed on the substrate and has a protruding portion protruding from the second insulating structure. The protruding portion of the first active semiconductor fin and the protruding portion of the second active semiconductor fin have different heights.

PRIORITY CLAIM AND CROSS-REFERENCE

This application is a continuation of U.S. patent application Ser. No.16/593,287, filed on Oct. 4, 2019, and entitled “FinFET with SlopedSurface at Interface between Isolation Structures and ManufacturingMethod Thereof”, which is a continuation of U.S. patent application Ser.No. 16/227,422, filed on Dec. 20, 2018, now U.S. Pat. No. 10,504,787,issued on Dec. 10, 2019, entitled “FinFET with Sloped Surface atInterface between Isolation Structures”, which is a continuation of U.S.patent application Ser. No. 15/905,429, filed on Feb. 26, 2018, andentitled “Method of Forming FinFET Device by Adjusting Etch Selectivityof Dielectric Layer”, now U.S. Pat. No. 10,163,717, issued on Dec. 25,2018, which is a divisional of U.S. patent application Ser. No.14/971,907, filed on Dec. 16, 2015, and entitled “Semiconductor Deviceand Manufacturing Method Thereof”, now U.S. Pat. No. 9,905,467, issuedon Feb. 27, 2018, which claims priority to U.S. Provisional PatentApplication No. 62/214,759 filed on Sep. 4, 2015, and entitled “N/PMOSImplant Induced Fin Height Loading Effect,” which applications areincorporated herein by reference.

BACKGROUND

Semiconductor integrated circuit (IC) industry has experiencedexponential growth. Technological advances in IC materials and designhave produced generations of ICs where each generation has smaller andmore complex circuits than the previous generation. In the course of ICevolution, functional density (i.e., the number of interconnecteddevices per chip area) has generally increased while geometry size(i.e., the smallest component (or line) that can be created using afabrication process) has decreased. This scaling down process generallyprovides benefits by increasing production efficiency and loweringassociated costs.

Such scaling down has also increased the complexity of processing andmanufacturing ICs and, for these advances to be realized, similardevelopments in IC processing and manufacturing are needed. For example,a three dimensional transistor, such as a fin-like field-effecttransistor (FinFET), has been introduced to replace a planar transistor.The fin transistor has a channel (referred to as a fin channel)associated with a top surface and opposite sidewalls. The fin channelhas a total channel width defined by the top surface and the oppositesidewalls.

BRIEF DESCRIPTION OF THE DRAWINGS

Aspects of the present disclosure are best understood from the followingdetailed description when read with the accompanying figures. It isnoted that, in accordance with the standard practice in the industry,various features are not drawn to scale. In fact, the dimensions of thevarious features may be arbitrarily increased or reduced for clarity ofdiscussion.

FIGS. 1A to 1H are cross-sectional views of a method for manufacturing asemiconductor device at various stages in accordance with someembodiments of the present disclosure.

FIG. 2A is an enlarged view of area A in FIG. 1G.

FIG. 2B is an enlarged view of area B in FIG. 1G.

FIG. 3 is a cross-sectional view of a semiconductor device in accordancewith some embodiments of the present disclosure.

DETAILED DESCRIPTION

The following disclosure provides many different embodiments, orexamples, for implementing different features of the provided subjectmatter. Specific examples of components and arrangements are describedbelow to simplify the present disclosure. These are, of course, merelyexamples and are not intended to be limiting. For example, the formationof a first feature over or on a second feature in the description thatfollows may include embodiments in which the first and second featuresare formed in direct contact, and may also include embodiments in whichadditional features may be formed between the first and second features,such that the first and second features may not be in direct contact. Inaddition, the present disclosure may repeat reference numerals and/orletters in the various examples. This repetition is for the purpose ofsimplicity and clarity and does not in itself dictate a relationshipbetween the various embodiments and/or configurations discussed.

Further, spatially relative terms, such as “beneath,” “below,” “lower,”“above,” “upper” and the like, may be used herein for ease ofdescription to describe one element or feature's relationship to anotherelement(s) or feature(s) as illustrated in the figures. The spatiallyrelative terms are intended to encompass different orientations of thedevice in use or operation in addition to the orientation depicted inthe figures. The apparatus may be otherwise oriented (rotated 90 degreesor at other orientations) and the spatially relative descriptors usedherein may likewise be interpreted accordingly.

Examples of devices that can be improved from one or more embodiments ofthe present application are semiconductor devices. Such a device, forexample, is a FinFET device. The FinFET device, for example, may be acomplementary metal-oxide-semiconductor (CMOS) device including at leastone P-type metal-oxide-semiconductor (PMOS) FinFET device and at leastone N-type metal-oxide-semiconductor (NMOS) FinFET device. The followingdisclosure will continue with a FinFET example to illustrate variousembodiments of the present application. It is understood, however, thatthe application should not be limited to a particular type of device.

FIGS. 1A to 1H are cross-sectional views of a method for manufacturing asemiconductor device at various stages in accordance with someembodiments of the present disclosure. Reference is made to FIG. 1A. Asubstrate 110 is provided. The substrate 110 has at least one firstregion 102 and at least one second region 104. For example, in FIG. 1A,the substrate 110 has one first region 102 and one second region 104adjacent to the first region 102. In some embodiments, the first region102 and the second region 104 are different regions selected from thegroup consisting essentially of a logic core region, a memory region(such as an embedded static random access memory (SRAM) region), ananalog region, an input/output (also referred to as a peripheral)region, a dummy region (for forming dummy patterns), and the like. Insome embodiments, the first region 102 is an n-type FinFET region, whilethe second region 104 is a p-type FinFET region, or vice versa. Inalternative embodiments, the first region 102 is a logic core region,while the second region 104 is an IO region, or vice versa.

In some embodiments, the substrate 110 includes silicon. Alternatively,the substrate 110 may include germanium, silicon germanium, galliumarsenide or other appropriate semiconductor materials. Alsoalternatively, the substrate 110 may include an epitaxial layer. Forexample, the substrate 110 may have an epitaxial layer overlying a bulksemiconductor. Further, the substrate 110 may be strained forperformance enhancement. For example, the epitaxial layer may include asemiconductor material different from that of the bulk semiconductor,such as a layer of silicon germanium overlying bulk silicon or a layerof silicon overlying bulk silicon germanium. Such strained substrate maybe formed by selective epitaxial growth (SEG). Furthermore, thesubstrate 110 may include a semiconductor-on-insulator (SOI) structure.Also alternatively, the substrate 110 may include a buried dielectriclayer, such as a buried oxide (BOX) layer, such as that formed byseparation by implantation of oxygen (SIMOX) technology, wafer bonding,SEG, or other appropriate method.

A plurality of semiconductor fins are formed on the substrate 110. Ingreater detail, the semiconductor fins includes at least one firstactive semiconductor fin 112 and at least one second activesemiconductor fin 114. For example, in FIG. 1A, there are four of thefirst active semiconductor fins 112 and four of the second activesemiconductor fins 114. The first active semiconductor fins 112 areformed on the first region 102 of the substrate 110, and the secondactive semiconductor fins 114 are formed on the second region 104 of thesubstrate 110. In some embodiments, the first active semiconductor fins112 and the second active semiconductor fins 114 include silicon. It isnote that the numbers of the first active semiconductor fins 112 and thesecond active semiconductor fins 114 in FIG. 1A are illustrative, andshould not limit the claimed scope of the present disclosure. A personhaving ordinary skill in the art may select suitable numbers for thefirst active semiconductor fins 112 and the second active semiconductorfins 114 according to actual situations.

The first active semiconductor fins 112 and the second activesemiconductor fins 114 may be formed, for example, by patterning andetching the substrate 110 using photolithography techniques. In someembodiments, a layer of photoresist material (not shown) is depositedover the substrate 110. The layer of photoresist material is irradiated(exposed) in accordance with a desired pattern (the first activesemiconductor fins 112 and the second active semiconductor fins 114 inthis case) and developed to remove a portion of the photoresistmaterial. The remaining photoresist material protects the underlyingmaterial from subsequent processing steps, such as etching. It should benoted that other masks, such as an oxide or silicon nitride mask, mayalso be used in the etching process.

In some embodiments, at least one dummy semiconductor fin 116 is formedon the substrate 110. For example, in FIG. 1A, there are ten dummysemiconductor fins 116. The dummy semiconductor fins 116 can be disposedin the first region 102 and/or the second region 104 of the substrate110, and can be disposed between the first active semiconductor fins 112and the second active semiconductor fins 114. The dummy semiconductorfins 116 have no functionality in the semiconductor device but make thedevice processes more uniform, more reproducible, and moremanufacturable. The first active semiconductor fins 112 and the secondsemiconductor fins 114 have functionality in the semiconductor device.

The dummy semiconductor fins 116 can be formed with the first activesemiconductor fins 112 and the second active semiconductor fins 114. Ingreater detail, a plurality of semiconductor fins with substantiallyequal spaced and substantially the same height are formed on thesubstrate 110 in advanced. Additional lithography and etch operationsare performed to remove (or cut) some of the fins, referred to as thedummy semiconductor fins 116. The lithography and etch operation can beperformed once or multiple times. The uncut semiconductor fins arereferred to as the first active semiconductor fins 112 and the secondactive semiconductor fins 114. That is, the heights H1 of the firstactive semiconductor fins 112 and the second active semiconductor finsH2 114 are greater than the heights H3 of the dummy semiconductor fins116. This operation can prevent different fin line profile includingboth critical dimensions and sidewall profile angle. However, in someother embodiments, the dummy semiconductor fins 116 can be omitted. Insome embodiments, the heights H1 and/or the heights H2 are about 100 nmto about 150 nm, and the claimed scope is not limited in this respect.

Reference is made to FIG. 1B. Dielectric material 120 is disposed on thesubstrate 110 and covers the first active semiconductor fins 112, thesecond active semiconductor fins 114, and the dummy semiconductor fins116. In some embodiments, the dielectric material 120 includes oxideand/or other dielectric materials. Optionally, a liner oxide (not shown)may be formed in advance. In some embodiments, the liner oxide may be athermal oxide. In some other embodiments, the liner oxide may be formedusing in-situ steam generation (ISSG). In yet some other embodiments,the liner oxide may be formed using selective area chemical vapordeposition (SACVD) or other commonly used CVD methods. The formation ofthe liner oxide reduces the electrical fields and hence improves theperformance of the resulting semiconductor device.

Reference is made to FIG. 1C. A chemical mechanical polish (CMP) isperformed to level the top surface of the dielectric material 120 to thetop surface of the semiconductor fins (i.e., the first activesemiconductor fins 112 and the second active semiconductor fins 114) toform a dielectric layer 120′. In other words, the dielectric material120′ covers the dummy semiconductor fins 116.

A protection layer 130 is formed on the dielectric material 120′ andcovers the first active semiconductor fins 112 and the second activesemiconductor fins 114. The protection layer 130 allows implantationtherethrough while preventing damage of the underlying structure (i.e.,the first active semiconductor fins 112, the second active semiconductorfins 114, and the dielectric material 120′). Examples of a suitableprotection layer 130 may be an oxide layer or include a SiO₂ or SiNlayer deposited by a CVD process, e.g., MOCVD, or an Al₂O₃ layer or ananolaminate layer, including a material such as HfO₂ and/or HfAlO,deposited by ALD.

Reference is made to FIG. 1D. A patterned mask layer 140 is formed onthe protection layer 130 and the second region 104 of the substrate 110.The patterned mask layer 140 can be a resist layer, which is alsoreferred to as a photoresist layer, photosensitive layer, imaging layer,patterning layer, or radiation sensitive layer. The patterned mask layer140 includes a positive-type resist material, a negative-type resistmaterial, other type material, or combinations thereof. The patternedmask layer 140 is formed on the protection layer 130 by a lithographyprocess. The lithography process includes resist coating (for example,spin-on coating), soft baking, mask aligning, exposure, post-exposurebaking, developing the resist, rinsing, drying (for example, hardbaking), other suitable processes, or combinations thereof.Alternatively, the lithography process is implemented or replaced byother methods, such as maskless lithography, electron-beam writing, orion-beam writing. In yet another alternative, the lithography processimplements nanoimprint technology to pattern the mask layer. In someembodiments, the lithography process implements an etching process, suchas a dry etching, wet etching, other etching method, or combinationsthereof. A rinsing process, such as a de-ionized (DI) water rinse, maybe performed on the protection layer 130 before forming the patternedmask layer 140.

The patterned mask layer 140 includes an opening 142 that exposes aportion of the protection layer 130 located on the first region 102 ofthe substrate 110. In FIG. 1D, an ion implantation process (or dopingprocess) 210 is performed on the dielectric layer 120′ using thepatterned mask layer 140 as a mask. In FIG. 1D, the ion implantationprocess 210 forms at least one first insulating structure 150 in thedielectric layer 120′. The ion implantation process 210 implants p-typedopants (such as boron (B), indium (In), aluminum (Al), gallium (Ga),IIIA group elements, or combinations thereof). In some embodiments, thefirst insulating structure 150 is an electrically isolation betweensemiconductor fins of a semiconductor device, such as a transistor. Theion implantation process 210 is performed at a suitable energy anddosage to achieve desired characteristics of the semiconductor device.In some embodiments, the implant dosage of the ion implantation process210 is about 8×10¹² ions/cm² to about 2×10¹⁴ ions/cm², and the energy ofthe ion implantation process 210 is about 20 keV to about 120 keV, andthe claimed scope is not limited in the respect.

Reference is made to FIG. 1E. The patterned mask layer 140 (see FIG. 1D)is removed. In some embodiments, the patterned mask layer 140 is removedby performing a wet etching process. In some embodiments, wet etchsolution for the wet etching process includes a Caros solution,including sulfuric acid (H₂SO₄) and peroxide (H₂O₂). Alternatively, thepatterned mask layer 140 is removed by a chemical solution selected fromO₃ water, sulfuric acid (H₂SO₄) and ozone (O₃), H₂SO₄ and H₂O₂,N-methyl-2-pyrrolidine (NMP), cyclohexanol, cyclopentanol, propyleneglycol monomethyl ether (PGME), and Propylene glycol monomethyl etheracetate (PGMEA). In some other embodiment, the patterned mask layer 140is removed by a chemical solution selected from oxidant based solution.In some embodiments, a cleaning process is performed to clean organicresidue or other residues after the removal of the patterned mask layer140. The cleaning material is capable of removing the organic residue.The cleaning material may include solvent, surfactant or polymeringredient.

Another patterned mask layer 145 is formed on the protection layer 130and the first region 102 of the substrate 110. The patterned mask layer145 can be a resist layer, which is also referred to as a photoresistlayer, photosensitive layer, imaging layer, patterning layer, orradiation sensitive layer. The patterned mask layer 145 includes apositive-type resist material, a negative-type resist material, othertype material, or combinations thereof. The patterned mask layer 145 isformed on the protection layer 130 by a lithography process. Thelithography process includes resist coating (for example, spin-oncoating), soft baking, mask aligning, exposure, post-exposure baking,developing the resist, rinsing, drying (for example, hard baking), othersuitable processes, or combinations thereof. Alternatively, thelithography process is implemented or replaced by other methods, such asmaskless lithography, electron-beam writing, or ion-beam writing. In yetanother alternative, the lithography process implements nanoimprinttechnology to pattern the mask layer. In some embodiments, thelithography process implements an etching process, such as a dryetching, wet etching, other etching method, or combinations thereof. Arinsing process, such as a de-ionized (DI) water rinse, may be performedon the protection layer 130 before forming the patterned mask layer 145.

The patterned mask layer 145 includes an opening 147 that exposes aportion of the protection layer 130 located on the second region 104 ofthe substrate 110. In FIG. 1E, another ion implantation process (ordoping process) 215 is performed on the dielectric layer 120′ using thepatterned mask layer 145 as a mask. In FIG. 1E, the ion implantationprocess 215 forms at least one second insulating structure 155 in thedielectric layer 120′. The ion implantation process 215 implants n-typedopants (such as nitrogen (N), phosphor (P), arsenic (As), antimony(Sb), VA group elements, or combinations thereof). In some embodiments,the second insulating structure 155 is an electrically isolation betweensemiconductor fins of a semiconductor device, such as a transistor. Theion implantation process 215 is performed at a suitable energy anddosage to achieve desired characteristics of the semiconductor device.In some embodiments, the implant dosage of the ion implantation process215 is about 8×10¹² ions/cm² to about 3×10¹⁴ ions/cm², and the energy ofthe ion implantation process 215 is about 20 keV to about 250 keV, andthe claimed scope is not limited in the respect.

Reference is made to FIG. 1F. The patterned mask layer 145 (see FIG. 1E)and the protection layer 130 (see FIG. 1E) are removed. In someembodiments, the patterned mask layer 145 is removed by performing a wetetching process. In some embodiments, wet etch solution for the wetetching process includes a Caros solution, including sulfuric acid(H₂SO₄) and peroxide (H₂O₂). Alternatively, the patterned mask layer 140is removed by a chemical solution selected from O₃ water, sulfuric acid(H₂SO₄) and ozone (O₃), H₂SO₄ and H₂O₂, N-methyl-2-pyrrolidine (NMP),cyclohexanol, cyclopentanol, propylene glycol monomethyl ether (PGME),and Propylene glycol monomethyl ether acetate (PGMEA). In some otherembodiment, the patterned mask layer 145 is removed by a chemicalsolution selected from oxidant based solution. In some embodiments, acleaning process is performed to clean organic residue or other residuesafter the removal of the patterned mask layer 145. The cleaning materialis capable of removing the organic residue. The cleaning material mayinclude solvent, surfactant or polymer ingredient.

In some embodiments, an annealing (referred to as diffusion annealinghereinafter) process can be performed after the patterned mask layer 145is removed. The annealing process is to force the dopants in the firstinsulating structures 150 and the second insulating structures 155 todiffuse. The diffusion annealing includes commonly used rapid thermalanneal (RTA) and solid phase epitaxy re-growth anneal. As a result ofthe diffusion annealing, the first insulating structures 150 and thesecond insulating structures 155 have much uniform dopant distributions.

Reference is made to FIG. 1G. The first insulating structures 150 andthe second insulating structures 155 are partially removed to exposeportions of the first active semiconductor fins 112 and portions of thesecond active semiconductor fins 114. The exposed portions of the firstactive semiconductor fins 112 are referred as protrusion portions 113 ofthe first active semiconductor fins 112, which protrude (or extend) fromthe first insulating structures 150. The exposed portions of the secondactive semiconductor fins 114 are referred as protrusion portions 115 ofthe second active semiconductor fins 114, which protrude (or extend)from the second insulating structures 155.

In some embodiments, the first insulating structures 150 and the secondinsulating structures 155 are partially removed by using at least oneetching process. The etching process can be a wet etching process, a dryetching process, or combinations thereof. The dry etching process can bea high selective etching process, plasma etching process,electron-cyclotron (ECR) plasma etching process, inductively coupledplasma (ICP) etching process, or other suitable etching process. Thepower of the dry etching process may be about 50 W to about 500 W, andthe etching gas may include C₂F₆, CF₄, CHF₃, or C₃F₈ with a flow rate ofabout 20 standard cubic centimeters per minute (sccm) to about 150 sccm,O₂ with a flow rate of about 20 sccm to 60 sccm, and He with a flow rateof about 50 sccm to about 200 sccm. The pressure of the dry etchingprocess is about 20 mTorr to about 200 mTorr. The temperature of the dryetching process is between room temperature to about 250° C. Thefrequency of the dry etching process is about 50 kHz to about 13.56 MHz.The operation time of the dry etching process is about 30 seconds toabout 150 seconds. The solution of the wet etching process includesdilute hydrofluoric acid (HF), such as 5:1 HF, 10:1 HF, 25:1 HF, or HFwith other suitable ratio. The temperature of the wet etching process isat room temperature. The operation time of the wet etching process isabout 5 seconds to about 50 seconds.

Since the first insulating structure 150 and the second insulatingstructure 155 include different dopants, the etching rates of the firstinsulating structures 150 and the second insulating structures 155 aredifferent. Hence, the thickness T1 of the first insulating structure 150is different from the thickness T2 of the second insulating structure155. For example, in FIG. 1G, the etching rate of the first insulatingstructures 150 is higher than the etching rate of the second insulatingstructure 155. Hence, the thickness T1 of the first insulating structure150 is less than the thickness T2 of the second insulating structure155. In addition, the top surface 152 of the first insulating structure150 and the top surface 157 of the second insulating structure 155 arenon-coplanar. Furthermore, for the first insulating structure 150 andthe second insulating structure 155 disposed adjacent to each other, thetop surface 152 of the first insulating structure 150 is sloped at aninterface I between the first insulating structure 150 and the secondinsulating structure 155. Also, the top surface 157 of the secondinsulating structure 155 is sloped at an interface I between the firstinsulating structure 150 and the second insulating structure 155.

Moreover, the protrusion portions 113 of the first active semiconductorfins 112 have heights H4 of about 20 nm to about 60 nm, and theprotrusion portions 115 of the second active semiconductor fins 114 haveheights H5 of about 20 nm to about 60 nm. The height H4 is differentfrom the height H5. For example, the height H4 is greater than theheight H5. The difference between the heights H4 and H5 is about 0.3 nmto about 6 nm, or about 0.3% to about 4% of heights H1 and/or H2 (seeFIG. 1A). Furthermore, the top surface 113 t of the first activesemiconductor fin 112 and the top surface 115 t of the second activesemiconductor fin 114 are substantially coplanar.

FIG. 2A is an enlarged view of area A in FIG. 1G. In FIG. 2A, the firstactive semiconductor fins 112 (see FIG. 1G) include outer fins 112 a andinner fins 112 b disposed between the outer fins 112 a. The outer fins112 a and the inner fins 112 b form a group G1. The outer fins 112 a aredisposed at the edges of the group G1. At least one of the protrusionportions 113 a of the outer fins 112 a has a height H4 a of about 20 nmto about 60 nm. At least one of the protrusion portions 113 b of theinner fins 112 b has a height H4 b of about 20 nm to about 60 nm. Theheight H4 b is greater than the height H4 b. The height differencebetween the protrusion portion 113 b and 113 a (i.e., H4 b-H4 a) isabout 1 nm to about 6 nm or about 7 nm to about 10 nm. In someembodiments, the heights H4 b of the protrusion portions 113 b of theinner fins 112 b are substantially the same.

In addition, the first insulating structures 150 (see FIG. 1G) includeouter insulating structures 150 a and inner insulating structures 150 bdisposed between the outer insulating structures 150 a. At least one ofthe inner insulating structures 150 b is disposed between adjacent twoof the first active semiconductor fins (i.e., the outer fins 112 aand/or the inner fins 112 b). One of the outer fins 112 a is disposedbetween one of the outer insulating structures 150 a and one of theinner insulating structures 150 b. In some embodiments, an acute angleθ1 is formed between the top surface 152 of the first insulatingstructure (i.e., the outer insulating structure 150 a and/or the innerinsulating structure 150 b in this case) and a sidewall 112 s of thefirst active semiconductor fin (i.e., the outer fin 112 a and/or theinner fin 112 b in this case). In some embodiments, the acute angle θ1is about 35 degrees to about 55 degrees.

FIG. 2B is an enlarged view of area B in FIG. 1G. In FIG. 2B, the secondactive semiconductor fins 114 (see FIG. 1G) include outer fins 114 a andinner fins 114 b disposed between the outer fins 114 a. The outer fins114 a and the inner fins 114 b form a group G2. The outer fins 114 a aredisposed at the edges of the group G2. At least one of the protrusionportions 115 a of the outer fins 114 a has a height H5 a of about 20 nmto about 60 nm. At least one of the protrusion portions 115 b of theinner fins 114 b has a height H5 b of about 20 nm to about 60 nm. Theheight H5 b is greater than the height H5 b. The height differencebetween the protrusion portion 115 b and 115 a (i.e., H5 b-H5 a) isabout 1 nm to about 6 nm or about 7 nm to about 10 nm. In someembodiments, the heights H5 b of the protrusion portions 115 b of theinner fins 114 b are substantially the same.

In addition, the second insulating structures 155 (see FIG. 1G) includeouter insulating structures 155 a and inner insulating structures 155 bdisposed between the outer insulating structures 155 a. At least one ofthe inner insulating structures 155 b is disposed between adjacent twoof the second active semiconductor fins (i.e., the outer fins 114 aand/or the inner fins 114 b). One of the outer fins 114 a is disposedbetween one of the outer insulating structures 155 a and one of theinner insulating structures 155 b. In some embodiments, an acute angleθ2 is formed between the top surface 157 of the second insulatingstructure (i.e., the outer insulating structure 155 a and/or the innerinsulating structure 155 b in this case) and a sidewall 114 s of thesecond active semiconductor fin (i.e., the outer fin 114 a and/or theinner fin 114 b in this case). In some embodiments, the acute angle θ2is about 35 degrees to about 55 degrees.

Reference is made to FIGS. 2A and 2B. In some embodiments, the height H4a of the protrusion portion 113 a of the outer fin 112 a is greater thanthe height H5 a of the protrusion portion 115 a of the outer fin 114 a.The height difference between the protrusion portion 113 a and 115 a(i.e., H4 a-H5 a) is about 1 nm to about 6 nm or about 7 nm to about 10nm. In some embodiments, the height H4 b of the protrusion portion 113 bof the inner fin 112 b is greater than the height H5 b of the protrusionportion 115 b of the inner fin 114 b. The height difference between theprotrusion portion 113 b and 115 b (i.e., H4 b-H5 b) is about 1 nm toabout 6 nm or about 7 nm to about 10 nm.

Reference is made to FIG. 1H. Gate dielectrics 160 and 165 are formed tocover the top surface and sidewalls of the protrusion portions 113 ofthe first active semiconductor fins 112 and the protrusion portions 115of the first active semiconductor fins 114, respectively. The gatedielectrics 160 and 165 may be formed by thermal oxidation, and hencemay include thermal silicon oxide. Gate electrodes 170 and 175 are thenformed on the gate dielectrics 160 and 165, respectively. In someembodiments, the gate electrode 170 covers more than one of the firstactive semiconductor fins 112 to form an n-type FinFET F1, and the gateelectrode 175 covers more than one of the second active semiconductorfins 114 to form a p-type FinFET F2. In alternative embodiments, atleast one of the first active semiconductor fins 112 and/or the secondactive semiconductor fins 114 may be used to form one FinFET.

FIG. 3 is a cross-sectional view of a semiconductor device in accordancewith some embodiments of the present disclosure. The difference betweenthe semiconductor devices of FIGS. 1G and 3 is the components of thesubstrate. In FIG. 3, the substrate 110 includes a first portion 106, asecond portion 107, and a third portion 108. The second portion 107 isdisposed on the first portion 106, and the third portion 108 is disposedon the second portion 107, such that the first portion 106, the secondportion 107, and the third portion 108 are stacked to form the substrate110. The first portion 106 and the second portion 107 have differentmaterial compositions, and the second portion 107 and the third portion108 have different material compositions. In some embodiments, the firstportion 106 and the third portion 108 of the substrate 110 are made ofsubstantially the same material. For example, the first portion 106 andthe third portion 108 of the substrate include silicon, such as bulksilicon, and the second portion 107 of the substrate 110 includessilicon, germanium, and oxide, such as SiGeO. Therefore, the firstportion 106, the second portion 107, and the third portion 108 formSi/SiGeO/Si stacked layers. Although in FIG. 3, at least one trench Tbetween adjacent semiconductor fins (i.e., the first activesemiconductor fins 112, the second active semiconductor fins 114, andthe dummy semiconductor fins 116) is formed in the third portion 108 ofthe substrate 110. That is, the bottom surface of the trench T is higherthan the interface of the second portion 107 and the third portion 108of the substrate 110. However, in some other embodiments, the trench Tcan expose the second portion 107 of the substrate 110, and the claimedscope is not limited in this respect. Other relevant structural detailsof the semiconductor device of FIG. 3 are similar to the semiconductordevice of FIG. 1G, and, therefore, a description in this regard will notbe repeated hereinafter.

According to the aforementioned embodiments, since the first insulatingstructure and the second insulating structure include different dopants,the etching rates of the first insulating structures and the secondinsulating structures are different. The height of the protrusionportion of the first active semiconductor fin is different from theheight of the protrusion portion of the second active semiconductor fin.That is, with at least one etching process, active semiconductor finswith different heights can be formed. By differentiating fin heights indifferent device regions, the junction window is increased, which meansthat the fin heights of FinFETs in different device regions are nolonger tied together. With the FinFETs in different device regionshaving different fin heights, it is easier to tune the performance ofdevices in different device regions.

According to some embodiments, a semiconductor device includes asubstrate, a first insulating structure, a second insulating structure,at least one first active semiconductor fin, and at least one secondactive semiconductor fin. The first insulating structure and the secondinsulating structure are disposed on the substrate. The first activesemiconductor fin is disposed on the substrate and has a protrudingportion protruding from the first insulating structure. The secondactive semiconductor fin is disposed on the substrate and has aprotruding portion protruding from the second insulating structure. Theprotruding portion of the first active semiconductor fin and theprotruding portion of the second active semiconductor fin have differentheights.

According to some embodiments, a semiconductor device includes asubstrate, a first insulating structure, a second insulating structure,at least one first active semiconductor fin, and at least one secondactive semiconductor fin. The first insulating structure is disposed onthe substrate and includes first dopants. The second insulatingstructure is disposed on the substrate and includes second dopantsdifferent from the first dopants of the first insulating structure. Thefirst active semiconductor fin is disposed on the substrate and extendsfrom the first insulating structure. The second active semiconductor finis disposed on the substrate and extends from the second insulatingstructure.

According to some embodiments, a method for manufacturing asemiconductor device includes forming at least one first activesemiconductor fin and at least one second active semiconductor fin on asubstrate. The substrate has a first region and a second region. Thefirst active semiconductor fin is disposed on the first region of thesubstrate, and the second active semiconductor fin is disposed on thesecond region of the substrate. A dielectric layer is formed on thefirst region and the second region of the substrate. A portion of thedielectric layer on the first portion of the substrate is doped withfirst dopants to form a first insulating structure. Another portion ofthe dielectric layer on the second portion of the substrate is dopedwith second dopants to form a second insulating structure. The seconddopants are different from the first dopants. At least a portion of thefirst insulating structure and at least a portion of the secondinsulating structure are recessed to expose a portion of the firstactive semiconductor fin and a portion of the second activesemiconductor fin.

One general aspect of embodiments disclosed herein includes a method formanufacturing a semiconductor device including: forming at least onefirst active semiconductor fin and at least one second activesemiconductor fin on a substrate, where the substrate has a first regionand a second region, the first active semiconductor fin is disposed onthe first region of the substrate, and the second active semiconductorfin is disposed on the second region of the substrate; forming adielectric layer on the first region and the second region of thesubstrate; doping a portion of the dielectric layer on the first regionof the substrate with first dopants to form a first insulatingstructure; doping another portion of the dielectric layer on the secondregion of the substrate with second dopants to form a second insulatingstructure, where the second dopants are different from the firstdopants; and recessing at least a portion of the first insulatingstructure and at least a portion of the second insulating structure toexpose a portion of the first active semiconductor fin and a portion ofthe second active semiconductor fin.

Another general aspect of embodiments disclosed herein includes a methodincluding: forming a first fin structure and a second fin structure;covering the first fin structure and the second fin structure with adielectric material; processing a region of the dielectric material tochange its etch selectivity characteristics relative to an un-processedregion of the dielectric material; and etching a top surface of thedielectric material to expose a first portion of the first fin structureand a second portion of the second fin structure, where the firstportion of the first fin structure has a height above the dielectricmaterial greater than a height of the second portion of the second finstructure above the dielectric material.

Yet another general aspect of embodiments disclosed herein includes amethod including: patterning a semiconductor substrate to include afirst plurality of first protruding structures and a second plurality ofsecond protruding structures; depositing an insulator over the firstplurality of first protruding structures and the second plurality ofsecond protruding structures, where the insulator has a first etch ratewhen exposed to a first etch process; processing a first region of theinsulator to change the first etch rate to a second etch rate, differentfrom the first etch rate, when the first region of the insulator isexposed to the first etch process, the first region being over the firstplurality of first protruding structures; processing a second region ofthe insulator to change the first etch rate to a third etch rate,different from the second etch rate, when the second region of theinsulator is exposed to the first etch process, the second region beingover the second plurality of second protruding structures; and exposingthe insulator to the first etch process to expose a first height ofrespective one of the first plurality of first protruding structures andto expose a second height of respective ones of the second plurality ofsecond protruding structures, the second height being less than thefirst height.

Yet another general aspect of embodiments disclosed herein includes adevice including: a substrate; a first isolation structure and a secondisolation structure over the substrate; a first active fin over thesubstrate and protruding above a first top surface of the firstisolation structure; and a second active fin over the substrate andprotruding above a second top surface of the second isolation structure,wherein the first top surface of the first isolation structure and thesecond top surface of the second isolation structure are sloped at aninterface between the first isolation structure and the second isolationstructure.

Yet another general aspect of embodiments disclosed herein includes adevice including: a substrate; a first isolation structure over thesubstrate, the first isolation structure comprising first dopants; asecond isolation structure over the substrate, the second isolationstructure comprising second dopants different from the first dopants; afirst active fin over the substrate and protruding above a first topsurface of the first isolation structure, a first protruding portion ofthe first active fin having a first height; and a second active fin overthe substrate and protruding above a second top surface of the secondisolation structure, a second protruding portion of the second activefin having a second height different from the first height.

Yet another general aspect of embodiments disclosed herein includes adevice including: a substrate; a first isolation structure over thesubstrate, the first isolation structure comprising p-type dopants; asecond isolation structure over the substrate, the second isolationstructure comprising n-type dopants; a first active fin over thesubstrate and protruding above a first top surface of the firstisolation structure, wherein a first acute angle is formed between thefirst top surface of the first isolation structure and a sidewall of thefirst active fin; and a second active fin over the substrate andprotruding above a second top surface of the second isolation structure,wherein a second acute angle is formed between the second top surface ofthe second isolation structure and a sidewall of the second active fin.

Yet another general aspect of embodiments disclosed herein includes adevice including: a substrate; a first dummy fin and a second dummy finover the substrate; a first isolation structure over the substrate andextending along sidewalls and a top surface of the first dummy fin; anda second isolation structure over the substrate and extending alongsidewalls and a top surface of the second dummy fin, wherein a topsurface of the first isolation structure and a top surface of the secondisolation structure are sloped at an interface between the firstisolation structure and the second isolation structure.

Yet another general aspect of embodiments disclosed herein includes adevice including: a substrate; a first dummy fin and a second dummy finover the substrate; a first isolation structure over the substrate andcovering the first dummy fin, the first isolation structure includingfirst dopants, the first isolation structure having a first thickness;and a second isolation structure over the substrate and covering thesecond dummy fin, the second isolation structure including seconddopants different from the first dopants, the second isolation structurebeing in physical contact with the first isolation structure, the secondisolation structure having a second thickness different from the firstthickness.

Yet another general aspect of embodiments disclosed herein includes amethod including: patterning a semiconductor substrate to form a firstactive semiconductor fin and a second active semiconductor fin; forminga dielectric layer over the semiconductor substrate, the first activesemiconductor fin and the second active semiconductor fin, wherein thedielectric layer includes a first region and a second region, the firstregion of the dielectric layer extending along a sidewall of the firstactive semiconductor fin, the second region of the dielectric layerextending along a sidewall of the second active semiconductor fin;doping the first region of the dielectric layer with first dopants;doping the second region of the dielectric layer with second dopantsdifferent from the first dopants; and recessing the first region and thesecond region of the dielectric layer below a top surface of the firstactive semiconductor fin and a top surface of the second activesemiconductor fin, wherein a first acute angle is formed between a topsurface of the first region of the dielectric layer and the sidewall ofthe first active semiconductor fin after the recessing, and wherein asecond acute angle is formed between a top surface of the second regionof the dielectric layer and the sidewall of the second activesemiconductor fin after the recessing.

Yet another general aspect of embodiments disclosed herein includes adevice including: a substrate; a first active fin and a first dummy finover the substrate; a first isolation structure over the substrate andextending along sidewalls of the first active fin, a top surface of thefirst active fin being above a top surface of the first isolationstructure; and a second isolation structure over the substrate andextending along sidewalls and a top surface of the first dummy fin,where the top surface of the first isolation structure and a top surfaceof the second isolation structure are sloped at an interface between thefirst isolation structure and the second isolation structure.

Yet another general aspect of embodiments disclosed herein includes adevice including: a substrate; a first active fin and a first dummy finover the substrate; a first isolation structure over the substrate andextending along a sidewall of the first active fin, the first isolationstructure including first dopants, the first isolation structure havinga first thickness, the first thickness being less than a height of thefirst active fin; and a second isolation structure over the substrateand covering the first dummy fin, the second isolation structureincluding second dopants different from the first dopants, the secondisolation structure being in physical contact with the first isolationstructure, the second isolation structure having a second thicknessdifferent from the first thickness.

Yet another general aspect of embodiments disclosed herein includes amethod including: patterning a semiconductor substrate to form a firstdummy semiconductor fin and a second dummy semiconductor fin; removingan upper portion of the first dummy semiconductor fin and an upperportion of the second dummy semiconductor fin; forming a dielectriclayer over the semiconductor substrate, the first dummy semiconductorfin and the second dummy semiconductor fin, where the dielectric layercomprises a first region and a second region, the first region of thedielectric layer covering the first dummy semiconductor fin, the secondregion of the dielectric layer covering the second dummy semiconductorfin; and recessing the first region and the second region of thedielectric layer, where a top surface of the first region and a topsurface of the second region are sloped at an interface between thefirst region and the second region after the recessing.

The foregoing outlines features of several embodiments so that thoseskilled in the art may better understand the aspects of the presentdisclosure. Those skilled in the art should appreciate that they mayreadily use the present disclosure as a basis for designing or modifyingother processes and structures for carrying out the same purposes and/orachieving the same advantages of the embodiments introduced herein.Those skilled in the art should also realize that such equivalentconstructions do not depart from the spirit and scope of the presentdisclosure, and that they may make various changes, substitutions, andalterations herein without departing from the spirit and scope of thepresent disclosure.

What is claimed is:
 1. A device comprising: a substrate; a first activefin and a first dummy fin over the substrate; a first isolationstructure over the substrate and extending along sidewalls of the firstactive fin, a top surface of the first active fin being above a topsurface of the first isolation structure; and a second isolationstructure over the substrate and extending along sidewalls and a topsurface of the first dummy fin, wherein the top surface of the firstisolation structure and a top surface of the second isolation structureare sloped at an interface between the first isolation structure and thesecond isolation structure.
 2. The device of claim 1, wherein the firstdummy fin has a concave top surface.
 3. The device of claim 1, whereinthe first dummy fin has a convex top surface.
 4. The device of claim 1,further comprising a second active fin over the substrate, the firstdummy fin being interposed between the first active fin and the secondactive fin, the second isolation structure extending along sidewalls ofthe second active fin, a top surface of the second active fin beingabove the top surface of the second isolation structure.
 5. The deviceof claim 1, further comprising a second dummy fin over the substrate,the second dummy fin being interposed between the first active fin andthe first dummy fin, the first isolation structure extending alongsidewalls and a top surface of the second dummy fin.
 6. The device ofclaim 5, wherein the second dummy fin has a concave top surface.
 7. Thedevice of claim 5, wherein the second dummy fin has a convex topsurface.
 8. A device comprising: a substrate; a first active fin and afirst dummy fin over the substrate; a first isolation structure over thesubstrate and extending along a sidewall of the first active fin, thefirst isolation structure comprising first dopants, the first isolationstructure having a first thickness, the first thickness being less thana height of the first active fin; and a second isolation structure overthe substrate and covering the first dummy fin, the second isolationstructure comprising second dopants different from the first dopants,the second isolation structure being in physical contact with the firstisolation structure, the second isolation structure having a secondthickness different from the first thickness.
 9. The device of claim 8,wherein the first dopants are p-type dopants, and wherein the seconddopants are n-type dopants.
 10. The device of claim 8, wherein a topsurface of the first isolation structure and a top surface of the secondisolation structure are sloped at an interface between the firstisolation structure and the second isolation structure.
 11. The deviceof claim 8, wherein the second thickness is greater than the firstthickness.
 12. The device of claim 8, further comprising a gatestructure extending along a top surface and the sidewall of the firstactive fin.
 13. The device of claim 8, wherein an acute angle is formedbetween a top surface of the first isolation structure and the sidewallof the first active fin.
 14. The device of claim 13, wherein the acuteangle is between 35 degrees and 55 degrees.
 15. A method comprising:patterning a semiconductor substrate to form a first dummy semiconductorfin and a second dummy semiconductor fin; removing an upper portion ofthe first dummy semiconductor fin and an upper portion of the seconddummy semiconductor fin; forming a dielectric layer over thesemiconductor substrate, the first dummy semiconductor fin and thesecond dummy semiconductor fin, wherein the dielectric layer comprises afirst region and a second region, the first region of the dielectriclayer covering the first dummy semiconductor fin, the second region ofthe dielectric layer covering the second dummy semiconductor fin; andrecessing the first region and the second region of the dielectriclayer, wherein a top surface of the first region and a top surface ofthe second region are sloped at an interface between the first regionand the second region after the recessing.
 16. The method of claim 15,further comprising: before recessing the first region and the secondregion of the dielectric layer, doping the first region of thedielectric layer with first dopants; and before recessing the firstregion and the second region of the dielectric layer doping the secondregion of the dielectric layer with second dopants different from thefirst dopants.
 17. The method of claim 16, wherein the first dopants arep-type dopants, and wherein the second dopants are n-type dopants. 18.The method of claim 15, wherein patterning the semiconductor substratefurther comprising forming a first active semiconductor fin and a secondactive semiconductor fin, wherein the first dummy semiconductor fin andthe second dummy semiconductor fin are interposed between the firstactive semiconductor fin and the second active semiconductor fin,wherein the first active semiconductor fin protrudes above a top surfaceof the first region after the recessing, and wherein the second activesemiconductor fin protrudes above a top surface of the second regionafter the recessing.
 19. The method of claim 15, wherein the firstregion and the second region have different thicknesses after therecessing.
 20. The method of claim 15, wherein a top surface of thefirst dummy semiconductor fin and a top surface of the second dummysemiconductor fin have different curvatures after removing the upperportion of the first dummy semiconductor fin and the upper portion ofthe second dummy semiconductor fin.